Golf Club Head with Grooves and Method of Manufacture

ABSTRACT

Embodiments of golf clubs with grooves and methods of manufacturing thereof are described herein. In some embodiments, a golf club head includes: a body having a strike face with one or more channels; and at least one insert located within at least one of the one or more channels. The at least one of the one or more channels includes a single groove. The at least one insert forms at least a portion of the single groove. A radius of an exterior edge of the single groove is partially formed by the at least one insert and is also partially formed by the strike face. A first part of the at least one insert is formed by a first material, and a second part of the at least one insert is formed by a second material different from the first material. Other embodiments and related methods are disclosed herein.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation application of U.S. patentapplication Ser. No. 13/045,178, filed Mar. 1, 2011, which is acontinuation U.S. Pat. No. 7,927,230, issued Apr. 19, 2011. U.S.application Ser. No. 13/045,178 and U.S. Pat. No. 7,927,230 areincorporated herein by reference.

TECHNICAL FIELD

This disclosure relates generally to golf equipment, and relates moreparticularly to golf clubs having grooves and methods of manufacture.

BACKGROUND

Typically, a golf club head can include a club face with a plurality ofparallel grooves extending between a toe end and a heel end of the clubface. In particular, the plurality of grooves in an iron-type club headcan “channel out” water, sand, grass, and/or other debris that may comebetween a golf ball and the club face. In some situations, this“channeling” can improve the grip between the golf ball and the clubface. The grooves can have various cross-sectional shapes such as asquare or rectangular shape, a V-shape, or a U shape.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 depicts a front view of a golf club having a golf club head and ashaft, according to a first embodiment;

FIG. 2 depicts a cross-sectional view of a groove of the golf club headof FIG. 1, taken along a section line 2-2 in FIG. 1, where thecross-sectional view shows a channel of the golf club head and aninsert;

FIG. 3 depicts a cross-sectional view of the channel of FIG. 2;

FIG. 4 depicts a cross-sectional view of the insert of FIG. 2;

FIG. 5 depicts a cross-sectional view of a channel of a golf club head,according to a second embodiment;

FIG. 6 depicts a cross-sectional view of an insert for the channel ofFIG. 5;

FIG. 7 depicts a cross-sectional view of the insert of FIG. 6 locatedwithin the channel of FIG. 5;

FIG. 8 depicts a cross-sectional view of a channel of a golf club head,according to a third embodiment;

FIG. 9 depicts a cross-sectional view of an insert for the channel ofFIG. 8;

FIG. 10 depicts a cross-sectional view of the insert of FIG. 9 locatedwithin the channel of FIG. 8;

FIG. 11 depicts a cross-sectional view of a channel of a golf club head,according to a fourth embodiment;

FIG. 12 depicts a cross-sectional view of an insert for the channel ofFIG. 11;

FIG. 13 depicts a cross-sectional view of the insert of FIG. 12 locatedwithin the channel of FIG. 11;

FIG. 14 depicts a cross-sectional view of the insert of FIG. 4 locatedwithin the channel of FIG. 11, according to fifth embodiment;

FIG. 15 depicts a cross-sectional view of another insert for the channelof FIG. 3, according to a sixth embodiment;

FIG. 16 depicts a cross-sectional view of the insert of FIG. 15 locatedwithin the channel of FIG. 3;

FIG. 17 depicts a cross-sectional view of a channel of a golf club head,according to a seventh embodiment;

FIG. 18 depicts a cross-sectional view of an insert for the channel ofFIG. 17;

FIG. 19 depicts a cross-sectional view of the insert of FIG. 18 locatedwithin the channel of FIG. 18;

FIG. 20 depicts a cross-sectional view of another insert for the channelof FIG. 3, according to an eighth embodiment;

FIG. 21 depicts a cross-sectional view of the insert of FIG. 20 locatedwithin the channel of FIG. 3;

FIG. 22 depicts a cross-sectional view of a channel of a golf club head,according to a ninth embodiment;

FIG. 23 depicts a cross-sectional view of an insert for the channel ofFIG. 22;

FIG. 24 depicts a cross-sectional view of the insert of FIG. 23 locatedwithin the channel of FIG. 22;

FIG. 25 depicts a cross-sectional view of another insert for the channelof FIG. 3, according to a tenth embodiment;

FIG. 26 depicts a cross-sectional view of the insert of FIG. 25 locatedwithin the channel of FIG. 3;

FIG. 27 depicts a cross-sectional view of the insert of FIG. 25 locatedwithin the channel of FIG. 3 after the insert is worn down, according toan eleventh embodiment;

FIG. 28 depicts a cross-sectional view of a channel of a golf club head,according to a twelfth embodiment;

FIG. 29 depicts a cross-sectional view of the insert of FIG. 4 locatedwithin the channel of FIG. 28;

FIG. 30 depicts a cross-sectional view of the insert of FIG. 4 locatedwithin a different embodiment of the channel of FIG. 28;

FIG. 31 depicts a flow chart of a method of manufacturing a golf clubaccording to a further embodiment; and

FIG. 32 depicts a cross-sectional view of an insert, according toanother embodiment.

For simplicity and clarity of illustration, the drawing figuresillustrate the general manner of construction, and descriptions anddetails of well-known features and techniques may be omitted to avoidunnecessarily obscuring of the drawings. Additionally, elements in thedrawing figures are not necessarily drawn to scale. For example, thedimensions of some of the elements in the figures may be exaggeratedrelative to other elements to help improve understanding of differentembodiments. The same reference numerals in different figures denote thesame elements.

The terms “first,” “second,” “third,” “fourth,” and the like in thedescription and in the claims, if any, are used for distinguishingbetween similar elements and not necessarily for describing a particularsequential or chronological order. It is to be understood that the termsso used are interchangeable under appropriate circumstances such thatthe embodiments of the golf club attachment mechanism and relatedmethods described herein are, for example, capable of operation insequences other than those illustrated or otherwise described herein.Furthermore, the terms “include,” and “have,” and any variationsthereof, are intended to cover a non-exclusive inclusion, such that aprocess, method, system, article, or apparatus that comprises a list ofelements is not necessarily limited to those elements, but may includeother elements not expressly listed or inherent to such process, method,article, or apparatus.

The terms “left,” “right,” “front,” “back,” “top,” “bottom,” “over,”“under,” and the like in the description and in the claims, if any, areused for descriptive purposes and not necessarily for describingpermanent relative positions. It is to be understood that the terms soused are interchangeable under appropriate circumstances such that theembodiments of the golf club attachment mechanism and related methodsdescribed herein are, for example, capable of operation in otherorientations than those illustrated or otherwise described herein. Theterm “coupled,” as used herein, is defined as directly or indirectlyconnected in a physical, mechanical, or other manner.

The terms “couple,” “coupled,” “couples,” “coupling,” and the likeshould be broadly understood and refer to connecting two or moreelements, either directly or indirectly through intervening elements.Coupling may be for any length of time, e.g., permanent orsemi-permanent or only for an instant. The absence of the word“removably,” “removable,” and the like near the word “coupled” and thelike does not mean that the coupling, etc. in question is or is notremovable.

DESCRIPTION

In one embodiment, a golf club head includes: a body having a strikeface with channels; and at least one insert located within at least oneof the channels. In this embodiment, the channel in which the insert islocated has a groove, and the insert forms at least a portion of thegroove. Other examples, embodiments, and related methods are furtherdescribed below.

Turning now to the figures, FIG. 1 depicts a front view of golf club100, according to a first embodiment. Golf club 100 can be an iron-typegolf club head, such as a 1-iron, a 2-iron, a 3-iron, a 4-iron, a5-iron, a 6-iron, a 7-iron, an 8-iron, a 9-iron, a sand wedge, a lobwedge, a pitching wedge, an n-degree wedge (e.g., 44 degrees (°), 48°,52°, 56°, 60°, etc.), etc. In a different embodiment, golf club 100 canalso be a wood-type golf club, a hybrid-type golf club, or a putter-typegolf club.

Golf club 100 includes golf club head body 110 and shaft 120 coupled togolf club head body 110. In the illustrated embodiment of FIG. 1, golfclub head body 110 includes hosel 114 to which shaft 120 is coupled. Ina different embodiment, golf club head body 110 has a hole, instead ofhosel 114, to which shaft 120 is coupled.

Golf club head body 110 includes toe portion 115 and heel portion 116,where hosel 114 is located at heel portion 116. Golf club head body 110also includes a perimeter 121 comprising sole 117 at a bottom portion ofgolf club head body 110 and also comprising top rail 118 at a topportion of golf club head body 110. Golf club head body 110 can alsoinclude notch 119 at heel portion 116.

Golf club head body 110 further includes back face 124 and front face111 opposite back face 124. Front face 111 can also be referred to as astrike face. The strike face can be an integral part of golf club headbody 110, or the strike face can be a separate piece from, or an insertfor, golf club head body 110. The strike face includes one or moregrooves 112, including groove 113. Grooves 112 can extend across thestrike face from toe portion 115 of golf club head body 110 to heelportion 116 of golf club head body 110. Grooves 112 can also be stackedvertically above one another from sole 117 to top rail 118, asillustrated in FIG. 1.

As explained in more detail in the subsequent figures, the strike faceincludes channels and inserts located within the channels. In oneembodiment, the inserts define grooves 112, and in a differentembodiment, the channels and inserts define different portions ofgrooves 112.

FIG. 2 depicts a cross-sectional view of groove 113 of golf club headbody 110 of FIG. 1, taken along a section line 2-2 in FIG. 1. Asdepicted in FIG. 2, golf club head body 110 includes a channel 210 thatis formed in strike face or front face 111, and insert 220 is locatedwithin channel 210. FIG. 3 depicts a cross-sectional view of channel210, and FIG. 4 depicts a cross-sectional view of insert 220. Thecross-sections of FIGS. 2-4 are taken along the widths of groove 113,channel 210, and insert 220. Insert 220 can extend along the entirelength of channel 210.

Grooves 112 (FIG. 1), including groove 113 (FIGS. 1, 2, and 4) can becompliant or non-compliant with, for example, the regulations regardinggrooves that were adopted by the United States Golf Association (USGA)on Aug. 5, 2008. As an example, when compliant with these regulations,grooves 112, including groove 113: (1) are straight and parallel witheach other; (2) have a symmetrical cross-section and have sidewalls thatdo not converge toward the groove opening; (3) have a width, spacing,and cross-section that is consistent throughout the impact area of frontface 111; (4) have a width that does not exceed 0.940 millimeters (mm)using the USGA's thirty degree method of measurement, and where lessthan half of the widths of grooves 112 exceed 0.889 mm using the samemeasurement technique; (5) have a distance between adjacent grooves thatis not less than three times the maximum width of the adjacent groovesminus 0.203 mm and that is not less than 1.854 mm, and where less thanhalf of the distances between adjacent ones of grooves 112 are less thanthree times the maximum width of the adjacent grooves and are less than1.905 mm; (6) have a depth that does not exceed 0.559 mm, and where lessthan half of the depths of grooves 112 exceed 0.508 mm; (7) have across-sectional area divided by a groove pitch (i.e., groove width plusspacing between adjacent grooves) that does not exceed 0.081 mm, andwhere the less than half of the cross-sectional areas divided by therespective groove pitches exceed 0.076 mm; (8) have a range of widthsthat do not exceed 0.254 mm; and (9) have a range of depths that do notexceed 0.254 mm. Additional details regarding grooves 112 are explainedin the subsequent figures.

In the embodiment illustrated in FIG. 2, insert 220 is located at andbelow front face 111 and is not located above front face 111. In oneexample of this embodiment, insert 220 can be located substantiallyplanar to front face 111. Also in this embodiment, insert 220 can form aportion of front face 111, or insert 220 can be devoid of forming aportion of front face 111. Furthermore, in this embodiment, the radiusof the edge of the groove can be formed entirely by insert 220, or theradius of the edge of the groove can be formed partially by front face111 and partially by insert 220. In another embodiment, insert 220 canbe located above and below front face 111. In a different embodiment,insert 220 is located only below front face 111. In this differentembodiment, the radius of the edge of the groove can be formed entirelyby front face 111, or the radius of the edge of the groove can be formedpartially by front face 111 and partially by insert 220.

In one embodiment, each of grooves 112 (FIG. 1) is formed by a separatepair of channel 210 and insert 220. In this embodiment, each channel 210has a single one of insert 220 and grooves 112 (FIG. 1), and each insert220 forms at least a portion of each of grooves 112. In a differentembodiment, golf club head body 110 (FIG. 1) has at least one channel,similar to channel 210, and at least one insert, similar to insert 220,is located within the at least one channel. In this differentembodiment, the at least one channel has a single groove, similar togrooves 113. In another embodiment, golf club head body 110 (FIG. 1) haschannels, similar to channel 210; a first insert, similar to insert 220,located within a first one of the channels; and a second insert, similarto insert 220, located within a second one of the channels. In thisembodiment, each of the first and second ones of the channels has asingle groove. Also, the first insert forms the single groove in thefirst one of the channels, and the second insert forms the single groovein the second one of the channels.

As illustrated in FIGS. 2-4, groove 113 is symmetrical about axis 290,which is an axis that is substantially perpendicular to the widths ofgroove 113, channel 210, and insert 220. In this embodiment, channel 210and insert 220 are also symmetrical about axis 290. In otherembodiments, some of which are illustrated in subsequent figures, one ormore of channel 210 and insert 220 are asymmetrical about axis 290 whilegroove 113 is symmetrical about axis 290.

Similarly, as illustrated in FIGS. 2 and 4, groove 113 comprises a firstcross section across a width of groove 113, and as illustrated in FIGS.2 and 3, channel 210 comprises a second cross section across a width ofchannel 210 that is non-proportional to the first cross section. Inother embodiments, some of which are illustrated in subsequent figures,the second cross section can be proportional to the first cross section.

In addition to the first cross section of groove 113 and the secondcross section of channel 210, insert 220 comprises a third cross sectionacross a width of insert 220, as illustrated in FIGS. 2 and 4. Each ofthese three cross sections comprises a cross-sectional area. In theembodiment of FIGS. 2-4, the cross-sectional area of the second crosssection of channel 210 is approximately equal to a sum of thecross-sectional areas of the first and third cross sections of groove113 and insert 220, respectively. In this embodiment, insert 220 can besecured within channel 210 by a friction fit. In some embodiments, anadhesive is disposed within channel 210 to further secure insert 220within channel 210. As an example, the adhesive can comprise Loctite®adhesives (from Henkel Corporation in Gulph Mills, Pa.), epoxies, andother types of adhesives. When an adhesive is used within channel 210,insert 220 does not need to have a friction fit with channel 210.Accordingly, in some embodiments, no adhesive is used within channel 210when insert 220 is secured within channel 210 by a friction fit. Inother embodiments, where insert 220 does not have a friction tit withchannel 210, an adhesive is used within channel 210.

In a different embodiment illustrated in a subsequent figure, thecross-sectional area of the cross section of the channel (e.g., channel1110 in FIGS. 11 and 14) is greater than a sum of the cross-sectionalareas of the first and third cross sections of groove 113 and insert220, respectively. In this different embodiment, a greater amount ofadhesive can be used within the channel than for channel 210 to improvethe coupling between the channel and insert 220.

As illustrated in FIGS. 2 and 4, insert 220 is a single or unitarypiece. In other embodiments, some of which are illustrated in thesubsequent figures, the insert can include two or more pieces. In thesame or different embodiment, some of the channels in a golf club headbody can have inserts while other channels in the golf club head body donot have any inserts. Also, for the channels that do have one or moreinserts, some of the channels can have a different number of inserts ora different type or shape of insert than other channels, or each of thechannels that have inserts can have the same insert(s).

As also illustrated in FIGS. 2 and 4, insert 220 can form all of groove113. In other embodiments, some of which are illustrated in thesubsequent figures, the insert can form part of the groove, and thechannel can form a different part of the groove.

In some embodiments, insert 220 can be referred to as a preform becauseinsert 220 is formed before being inserted into channel 210. In the sameor different embodiment, groove 113 can be formed into the preform orinsert 220 before or after forming the preform or insert 220 and alsobefore or after inserting the preform or insert 220 into channel 210. Insome embodiments, insert 220 can have more than one groove, anddifferent inserts of a golf club head can have a different number ofgrooves.

Regardless of whether the strike face of golf club head body 110(FIG. 1) is integral with or a separate piece from golf club head body110, the strike face can comprise a first material such as stainlesssteel, titanium, graphite, a composite of metallic and non-metallicmaterials, and the like. In some embodiments, insert 220 also comprisesthe first material, but in other embodiments, insert 220 comprises asecond material different from the first material. As an example, thesecond material can be softer than, harder than, or the same hardness asthe first material. In one embodiment illustrated in a subsequent figure(e.g., FIG. 27), the second material wears faster than the firstmaterial. Examples of the second material include aluminum, a resin, aplastic, titanium, a different grade of stainless steel than used forthe first material, a composite, and the like. In one embodiment, thefirst material comprises a first grade of stainless steel, and thesecond material comprises a second grade of stainless steel that is moreeasily machined and/or extruded than the first grade of stainless steel.In another embodiment, the second material comprises a tacky or stickymaterial.

In some embodiments, insert 220 is not permanent and can be replaceableso that new inserts and/or different inserts can be placed into thechannels. In other embodiments, insert 220 is permanently affixed withinchannel 210.

Turning to the next illustrated embodiment, FIG. 5 depicts across-sectional view of channel 510 of a golf club head, and FIG. 6depicts a cross-sectional view of insert 620. FIG. 7 depicts across-sectional view of insert 620 located within channel 510. Thisillustrated embodiment is similar to the embodiment illustrated FIGS.2-4, but in the embodiment of FIGS. 5-7, channel 510 and insert 620 areasymmetric about axis 290 while groove 113 is symmetric about axis 290.

In another illustrated embodiment, FIG. 8 depicts a cross-sectional viewof channel 810 of a golf club head, and FIG. 9 depicts a cross-sectionalview of insert 920. FIG. 10 depicts a cross-sectional view of insert 920located within channel 810. This embodiment is similar to the embodimentof FIGS. 2-4, but in the embodiment of FIGS. 8-10, channel 810 andinsert 920 are asymmetric about axis 290 while groove 113 is symmetricabout axis 290.

In a further illustrated embodiment, FIG. 11 depicts a cross-sectionalview of channel 1110 of a golf club head, and FIG. 12 depicts across-sectional view of insert 1220. FIG. 13 depicts a cross-sectionalview of insert 1220 located within channel 1110. This embodiment is alsosimilar to the embodiment of FIGS. 2-4. The embodiments of FIGS. 8-10and FIGS. 11-13, however, can more securely hold their respectiveinserts in their respective channels than the embodiment of FIGS. 2-3because of the configurations of channel 810 in FIG. 8 and channel 1110in FIG. 11. For example, the opening of channel 810 (FIG. 8) at frontface 111 is narrower than a bottom of channel 810, and the opening ofchannel 1110 (FIG. 11) at front face 111 is also narrower than a bottomof channel 1110. Correspondingly, a top of insert 920 (FIG. 9) isnarrower than a bottom of insert 920, and a top of insert 1220 (FIG. 12)is narrower than a bottom of insert 1200. In a different embodiment,insert 1220 in FIG. 12 can be replaced with insert 3220 in FIG. 32.Insert 3220 (FIG. 32) is similar to insert 1220 (FIG. 12), except thatinsert 3220 comprises two pieces, namely, insert 3221 and 3222 (FIG.32). The use of insert 3220 (FIG. 32), instead of insert 1220 (FIG. 12),in channel 1110 (FIG. 11) can facilitate the insertion of the insertinto the channel.

Next, FIG. 14 depicts a cross-sectional view of insert 210 of FIG. 4located within channel 1110 of FIG. 11, according to another embodiment.This embodiment is also similar to the embodiment of FIGS. 2-4. In theembodiment of FIG. 14, however, the cross-sectional area of channel 1110is greater than the sum of the cross-sectional areas of insert 220 andgroove 113. In particular, the cross-sectional area of channel 1110 isgreater than the sum of the cross-sectional areas of insert 220 andgroove 113 by a cross-sectional area of one or more gaps or residualregions 1444. In this embodiment, an adhesive can be disposed in channel1110, and at least a portion of the adhesive can be located withinresidual regions 1444. The presence of residual regions 1444 permits theuse of more adhesive in this embodiment of FIG. 14 than in theembodiment of FIGS. 2-4 and other embodiments. The use of more adhesivecan more securely hold insert 220 within channel 1110. As an example, aportion of residual regions 1444 can have a width of approximately 0.3mm to 0.1 mm. In this embodiment, the adhesive can be an epoxy.

Turning to a different embodiment, FIG. 15 depicts a cross-sectionalview of insert 1520, and FIG. 16 depicts a cross-sectional view ofinsert 1520 located within channel 210 of FIG. 3. This embodiment isalso similar to the embodiment of FIGS. 2-4, but in the embodiment ofFIGS. 15-16, groove 1613 is shallower than groove 113 in FIGS. 2-4.

FIG. 17 depicts a cross-sectional view of channel 1710 of a golf clubhead, according to a further embodiment, and FIG. 18 depicts across-sectional view of insert 1820 in this embodiment. FIG. 19 depictsa cross-sectional view of insert 1820 located within channel 1710. Thisembodiment is similar to the embodiment of FIGS. 2-4, but manydifferences between these two embodiments also exist. For example, inFIGS. 17-19, channel 1710 and insert 1920 are asymmetric about axis 290.Also, a portion of channel 1720 forms a portion of groove 113, and aportion of insert 1920 forms a different portion of groove 113. In oneexample of the illustrated embodiment of FIG. 19, an adhesive is used tocouple insert 1820 to channel 1710.

In this embodiment, insert 1820 can comprise a harder or softer materialthan strike face 111 of the golf club head body that forms channel 1710.For example, if a first edge of groove 113 that is closer to the sole ofthe golf club head body typically wears faster than a second edge ofgroove 113 that is closer to the top rail of the golf club head body,then insert 1820 can be located at the first edge of groove 113 and cancomprise a harder material than strike face 111. In this example, thefirst and second edges of groove 113 can wear more evenly with respectto each other. In a different example, if the first edge of groove 113typically wears slower than the second edge of groove 113, then insert1820 can still be located at the first edge of groove 113 if insert 1820comprises a softer material than the strike face. Other variations arealso possible.

Referring to the next embodiment, FIG. 20 depicts a cross-sectional viewof insert 2020, and FIG. 21 depicts a cross-sectional view of insert2020 located within channel 210 of FIG. 3. This embodiment is alsosimilar to the embodiment of FIGS. 2-4, but in FIGS. 20-21, insert 2020comprises two pieces or inserts 2021 and 2022. In the embodiment ofFIGS. 20-21, each piece of insert 2020 forms a different portion ofgroove 2113. Groove 2113 can be shallower than groove 113 in FIGS. 2 and3. In a different embodiment, insert 2020 can comprise three or morepieces, and each piece of insert 2020 can form a portion of groove 2113.In another embodiment, insert 2020 can comprise two or more pieces, andone or more of the pieces of insert 2020 forms groove 2113 while one ormore other pieces of insert 2020 do not form a portion of groove 2113.As another variation, one or more portions of the channel can also forma portion of the groove. Furthermore, the different pieces of insert2020 can comprise the same material or can comprise different materials.For example, for reasons similar to those explained with reference tothe previous embodiment of FIGS. 17-19, insert 2021 can comprise a firstmaterial, and insert 2022 can comprise a second material that is harderthan the first material. In one example of the illustrated embodiment inFIG. 21, an adhesive can be used to couple inserts 2021 and 2022 tochannel 210.

Next, FIG. 22 depicts a cross-sectional view of channel 2210 of a golfclub head, according to another embodiment, and FIG. 23 depicts across-sectional view of insert 2320 in this embodiment. FIG. 24 depictsa cross-sectional view of insert 2320 located within channel 2210. Thisembodiment is also similar to the embodiment of FIGS. 2-4, but in theembodiment of FIGS. 22-24, groove 2313 comprises a cross section thatcan be substantially proportional to a cross section of channel 2210. Inone example of the illustrated embodiment of FIG. 24, an adhesive can beused to couple insert 2320 to channel 2210.

FIG. 25 depicts a cross-sectional view of insert 2520 according toanother embodiment, and FIG. 26 depicts a cross-sectional view of insert2520 located within channel 210 of FIG. 3. This embodiment is alsosimilar to the embodiment of FIGS. 2-4, but as illustrated in FIGS.25-26, groove 2513 has a different shape than groove 113 in FIGS. 2 and4. In one embodiment of FIGS. 25-26, among other embodiments, thematerial used for insert 2520 can be softer than the material used forstrike face or front face 111. In this embodiment, FIG. 27 depicts across-sectional view of insert 2520 after being worn down such that theedges of grooves 2513 can become sharper as an individual uses the golfclub more. In another embodiment, an upper portion of insert 2520 cancomprise a softer material than a lower portion of insert 2520 to bettercontrol the amount of “wearing down” that insert 2520 will exhibit overtime. As an example, the harder material of the lower portion of insert2520 can be similar to the material used for front face 111, or theharder material of the lower portion of insert 2520 can be a differentmaterial that is either harder or softer than the material used forfront face 111. Furthermore, insert 2520 can be divided into two or morepieces, similar to the embodiment illustrated in FIGS. 20 and 21 forreasons similar to those discussed with respect to FIGS. 20-21 and/orFIGS. 17-19.

FIG. 28 depicts a cross-sectional view of channel 2810 of a golf clubhead, according to another embodiment, and FIG. 29 depicts across-sectional view of insert 220 of FIG. 4 located within channel2810. This embodiment is similar to the embodiment of FIGS. 2-4, but asillustrated in FIG. 29, a gap or residual region 2844 exists in channel2810 after insert 220 is inserted into channel 2810, which is similar tothe embodiment of FIG. 14. FIG. 30 depicts a cross-sectional view ofinsert 220 of FIG. 4 located within channel 3010, which is a differentembodiment of channel 2810 in FIGS. 28 and 29. One or more gaps orresidual regions 3044 and 3045 exist in channel 3010 after insert 220 isinserted into channel 3010.

FIG. 31 depicts flow chart 3100 of a method of manufacturing a golf clubaccording to a further embodiment. As an example, the golf club of flowchart 3100 can be similar to golf club 100 in FIG. 1. Flow chart 3100includes providing a body having a strike face with channels (block3110). As an example, the body of block 3110 can be similar to golf clubhead body 110 in FIG. 1, and the strike face and channels of block 3110can be similar to front face 111 and channel 210 in FIGS. 2 and 3. Thechannels of block 3110 can also be similar to the other channelsdescribed herein.

In one embodiment of block 3110, the body can be cast, forged, ormachined. In the same or different embodiment of block 3100, the strikeface of the golf club head body can have one or more channels, and atleast one of the channels can be symmetrical or non-symmetrical. Theother variations of the body, strike face, and channel(s) describedabove in FIGS. 1-30 can also be part of block 3110.

Flow chart 3100 also includes providing at least one preform or insert(a block 3120). As an example, the at least one preform or insert ofblock 3120 can be similar to insert 220 of FIGS. 2 and 4. The preform(s)or insert(s) of block 3120 can also be similar to the other preforms andinserts described herein. The sequence of blocks 3110 and 3120 can bereversed.

The preform(s) and insert(s) can be extruded, cast, forged, injected,deposited (i.e., vapor deposition, sputtering, etc.), or machined. Inone embodiment, the preform(s) or insert(s) are extruded from aluminum.In this embodiment, block 3120 can include providing the preform(s) orinsert(s) to comprise a different material from the material of thestrike face. In a different embodiment, block 3120 can include providingthe preform(s) or insert(s) to comprise the same material as the strikeface.

In the same or different embodiment, the preform(s) or insert(s) ofblock 3120 can have a size that is larger than a size of the channels(block 3110) into which the preform(s) or insert(s) are inserted. In oneembodiment, the preform(s) or insert(s) can have a width that isslightly larger than the width of the channels. For example, thechannels can have a substantially constant width of approximately 0.2 mmto 0.010 mm. In this example, a bottom of the insert(s) can haveapproximately the same width as the width of the channels, but the widthof the insert(s) can taper outwardly by approximately 0.5-2.0 degrees(in one embodiment) to slightly and/or gradually increase the width ofthe insert(s) from the bottom of the insert(s) to the top of theinsert(s). Both sides of the insert(s) can be tapered, or only one sideof the insert(s) can be tapered. In another example, the insert(s) canhave a substantially constant width, and the bottom of the channels canhave approximately the same width as the width of the insert(s), but thewidth of the channels can taper inwardly by approximately 0.5-2.0degrees (in one embodiment) to slightly and/or gradually decrease thewidth of the channels from the bottom of the channels to the top of thechannels. Both sides of the channels can be tapered, or only one side ofthe channels can be tapered. In a further example, the insert(s) cantaper outwardly from bottom to top, and the channels can taper inwardlyfrom bottom to top. In another example, one or more of the length andwidth of the inserts and/or the channels is tapered. In a furtherembodiment, one or more of the length and width of the inserts is nottapered, but is slightly larger than the corresponding length and/orwidth of the channels by a magnitude that is similar to what isdescribed above for the tapered embodiment. The other variations of theinsert(s) and preform(s) described above in FIGS. 1-30 can also be partof block 3120.

Flow chart 3100 continues with an optional heating of the body (optionalblock 3130) and an optional cooling of the insert(s) or preform(s)(optional block 3140). The sequence of blocks 3130 and 3140, if used inflow chart 3100, can be reversed. In a different embodiment, only one ofblocks 3130 and 3140 or none of blocks 3130 or 31.40 is used in flowchart 3100.

As an example where the channel length is more than three times thechannel width, the body and/or strike face can be heated to atemperature of approximately thirty-five to one hundred fifty degreesCelsius above room temperature in block 3130, or cooled to a temperatureof approximately thirty-five to one hundred fifty degrees Celsius (° C.)below room temperature in block 3140. More specifically, in oneembodiment where the strike face comprises 17:4 stainless steel (i.e.,17 percent (%) chromium and 4% nickel) and where the insert comprisestungsten carbide, the strike face can be heated to a temperature ofapproximately 100-150° C. above room temperature. In another embodimentwhere the strike face comprises 17:4 stainless steel and where theinsert comprises aluminum, the strike face can be heated to atemperature of approximately 35-100° C. above room temperature, and theinsert can be cooled to a temperature of approximately 5-50° C. belowroom temperature. In a further embodiment where the strike facecomprises 17:4 stainless steel and where the insert comprises stainlesssteel, the strike face can be heated to a temperature of approximately35-100° C. above room temperature, and the insert can be cooled to atemperature of approximately 35-100° C. below room temperature. In theseexamples, the width of the insert or preform can be the same as orslightly larger than the width of the channel while the length of theinsert and the channel remain approximately the same. Also in theseexamples, the insert or preform can be a single piece or multiplepieces. One or more of blocks 3130 and 3140 can be particularly usefulfor the embodiments of FIGS. 8-10, FIGS. 11-13, and any of theembodiments with a friction fit.

Flow chart 3100 also includes an optional disposing of an adhesive inthe channel(s) (optional block 3150). As an example, the adhesive ofblock 3150 can be similar to the adhesive described with respect toFIGS. 2-4. If used in flow chart 3100, block 3150 can occur before,after, or during, one or more of blocks 3130 and 3140.

Next, flow chart 3100 continues with inserting the preform(s) within thechannel(s) (block 3160). When blocks 3130 and 3140 are used, block 3160occurs during or after blocks 3130 and 3140. When block 3130 is used,block 3160 can include inserting the insert(s) or preform(s) within thechannel(s) before the body cools down to room temperature. When block3140 is used, block 3160 can include inserting the insert(s) orpreform(s) within the channel(s) before the body warms up to roomtemperature. The preform(s) can be secured within the channel(s) byusing a friction fit regardless of whether block 3150 is used in flowchart 3100.

In some embodiments, after block 3160, the channel(s) comprise a singlegroove, and the insert(s) or preform(s) form at least a portion of thesingle groove. Also, as explained above, the single groove can besymmetrical.

Flow chart 3100 also includes coupling a shaft to the body (block 3170).As an example, the shaft of block 3170 can be similar to shaft 120 ofFIG. 1. Block 3170 can occur before, after, or during any of blocks3120, 3130, 3140, 3150, and 3160.

Although golf club heads with grooves and methods of manufacture thereofhave been described with reference to specific embodiments, variouschanges may be made without departing from the scope of the golf clubhead with grooves and related methods. Various examples of such changeshave been given in the foregoing description. As another example, theshapes and configurations of the channels, inserts, and grooves can varyfrom the specific shapes and configurations disclosed herein. Forinstance, the configuration of the channels and inserts can be designedto keep the insert within the channel when a golf ball impacts thestrike face, such as where the channel has curved sidewalls and wherethe insert has complementarily curved sidewalls. As a further example, agolf club head can have more than one shape or configuration of channelsand/or inserts while having substantially constant or uniform grooves.Moreover, one or more of the features of one or more embodimentsdisclosed herein can be combined with some or all of the features of adifferent embodiment disclosed herein. Accordingly, the disclosure ofembodiments is intended to be illustrative of the scope of theapplication and is not intended to be limiting. It is intended that thescope of this application shall be limited only to the extent requiredby the appended claims. Therefore, the detailed description of thedrawings, and the drawings themselves, disclose at least one preferredembodiment of a golf club head with grooves and methods of manufacturethereof, and may disclose alternative embodiments of the same.

All elements claimed in any particular claim are essential to the golfclub head with grooves and methods of manufacture thereof claimed inthat particular claim. Consequently, replacement of one or more claimedelements constitutes reconstruction and not repair. Additionally,benefits, other advantages, and solutions to problems have beendescribed with regard to specific embodiments. The benefits, advantages,solutions to problems, and any element or elements that may cause anybenefit, advantage, or solution to occur or become more pronounced,however, are not to be construed as critical, required, or essentialfeatures or elements of any or all of the claims.

Moreover, embodiments and limitations disclosed herein are not dedicatedto the public under the doctrine of dedication if the embodiments and/orlimitations: (1) are not expressly claimed in the claims; and (2) are orare potentially equivalents of express elements and/or limitations inthe claims under the doctrine of equivalents.

1. A golf club head comprising: a body having a strike face with one ormore channels; and at least one insert located within at least one ofthe one or more channels, wherein: the at least one of the one or morechannels comprises a single groove; the at least one insert forms atleast a portion of the single groove; a radius of an exterior edge ofthe single groove is partially formed by the at least one insert and isalso partially formed by the strike face; a first part of the at leastone insert is formed by a first material; and a second part of the atleast one insert is formed by a second material different from the firstmaterial.
 2. The golf club head of claim 1, wherein: the radius of theexterior edge of the single groove comprises an area at the exterioredge of the single groove.
 3. The golf club head of claim 1, wherein:the at least one insert forms a first portion of the radius of theexterior edge of the single groove inside the single groove; and thestrike face forms a second portion of the radius of the exterior edge ofthe single groove outside the single groove.
 4. The golf club head ofclaim 1, wherein: the second material is softer than the first material.5. The golf club head of claim 1, wherein: the at least one insertcomprises at least two inserts; the first part comprises a first insertof the at least two inserts; the second part comprises a second insertof the at least two inserts; and the at least two inserts form at leasta portion of the single groove.
 6. The golf club head of claim 1,wherein: the strike face comprises a third material; and the thirdmaterial is identical to one of the first material or the secondmaterial.
 7. The golf club head of claim 1, further comprising: anadhesive in the at least one of the one or more channels, wherein: theat least one of the one or more channels and the at least one insert arecoupled together by the adhesive.
 8. The golf club head of claim 1,wherein: the at least one of the one or more channels and the at leastone insert are coupled together by a friction tit.
 9. The golf club headof claim 1, wherein: a radius of a second exterior edge of the singlegroove is partially formed by the at least one insert and is alsopartially formed by the strike face.
 10. The golf club head of claim 1,wherein: the at least one of the one or more channels comprises a firstcross section; the single groove comprises a second cross section; thefirst cross section comprises a first cross-sectional area; the secondcross section comprises a second cross-sectional area; and the secondcross-sectional area is non-proportional to the first cross-sectionalarea.
 11. A golf club comprising: a golf club head having a strike facewith two or more channels; a first preform located within a first one ofthe two or more channels; a second preform located within a second oneof the two or more channels; and a shaft coupled to the golf club head,wherein: each of the first and second ones of the two or more channelscomprises a single groove; the first preform forms at least a portion ofthe single groove in the first one of the two or more channels; a radiusof each exterior edge of the single groove of the first one of the twoor more channels is partially formed by the strike face and is alsopartially formed by the first preform; the second preform forms at leasta portion of the single groove in the second one of the two or morechannels; and a radius of each exterior edge of the single groove of thesecond one of the two or more channels is partially formed by the strikeface and is also partially formed by the second preform.
 12. The golfclub of claim 1 wherein: the radius of each exterior edge of the singlegroove of the first one of the two or more channels comprises an area ateach exterior edge of the single groove of the first one of the two ormore channels; and the radius each exterior edge of the single groove ofthe second one of the two or more channels comprises an area at eachexterior edge of the single groove of the first one of the two or morechannels.
 13. The golf club of claim 12, wherein: the at least onesecond material is configured to wear faster than the first material.14. The golf club of claim 11, wherein: the first preform comprises afirst material and a second material; the second preform comprises thefirst material and the second material; and the first material is harderthan the second material.
 15. The golf club of claim 11, furthercomprising: an adhesive coupling together the golf club head and thefirst preform, wherein: a gap is located between the first one of thetwo or more channels and the first preform; and the adhesive is locatedat least partially in the gap.
 16. The golf club of claim 11, wherein:the first one of the two or more channels comprises a first crosssection across a width of the first one of the two or more channels; thesingle groove of the first one of the two or more channels comprises asecond cross section across a width of the single groove of the firstone of the two or more channels; the second one of the two or morechannels comprises the first cross section across a width of the secondone of the two or more channels; the single groove of the second one ofthe two or more channels comprises the second cross section across awidth of the single groove of the second one of the two or morechannels; the first cross section comprises a first cross-sectionalarea; the second cross section comprises a second cross-sectional area;and the second cross-sectional area is substantially proportional to thefirst cross-sectional area.
 17. A golf club comprising: a golf club headhaving a strike face comprising a first channel and a second channel; afirst insert located within the first channel; a second insert locatedwithin the second channel; and a shaft coupled to the golf club head,wherein: the strike face further comprises two first rims adjacent tothe first channel, a first groove located at the first channel, twosecond rims adjacent to the second channel, and a second groove locatedat the second channel; a radius of at least one external edge of thefirst groove is formed in part by one of the two first rims of thestrike face and also formed in part by the first insert; and a radius ofat least one external edge of the second groove is formed in part by oneof the two second rims of the strike face and also formed in part by thesecond insert.
 18. The golf club of claim 17, wherein: the radius of theat least one external edge of the first groove comprises an area at theat least one external edge of the first groove.
 19. The golf club ofclaim 17, wherein: a first part of the first insert comprises a firstmaterial; and a second part of the first insert comprises a secondmaterial different from the first material.
 20. The golf club of claim19, wherein: a first part of the second insert comprises the firstmaterial; and a second part of the second insert comprises the secondmaterial.